Optimization of Cement Grinding Operation in Ball Mills

Several energy efficient options for cement grinding are available today such as vertical roller mills, roller presses (typically in combination with a ball mill), and clinker pre-grinders with ball mills. Ball mills have been the traditional method of comminution in the mineral processing industries and continue to operate with old generation classifiers, their maintenance sometimes neglected. This in combination with an inefficient operation translates into high energy consumption and low production.

The consumption of energy by the cement grinding operation amounts to one third of the total electrical energy used for the production of cement. The optimization of this process would yield substantial benefits in terms of energy savings and capacity increase.

Optimization of the Cement Ball Mill Operation

Optimization addresses the grinding process, maintenance and product quality. The objective is to achieve a more efficient operation and increase the production rate as well as improve the run factor. Consistent quality and maximum output with lower specific power consumption results in lower operating costs per unit of production. Optimization can also reduce the cost of liners and grinding media.

The cost of optimization is minimal since inspecting the mill and the resulting modifications — such as re-grading the grinding media or moving the diaphragm are labor elements that can be handled by the plant’s maintenance crew. Upgrading the classifier and baghouse involves capital expenditure with a high benefit to cost ratio.

Optimization is especially important when multiple products are being produced.